Span Block Sensor for Drilling Rig Load Measurement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current drilling operations lack effective means to accurately measure and adjust for the load applied to top drives during well drilling, leading to potential misalignment and inefficient drilling processes.
Innovation Solution
A system comprising a span block with sensor blocks positioned circumferentially to measure load applied to top drives, providing feedback for a control system to adjust drilling operations based on strain and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If no load measurement device is installed on the top drive, then the device complexity is low, but the measurement precision of load is insufficient leading to potential misalignment and inefficient drilling
Solution Approach 1:
A span block is introduced as an intermediary component between the top drive and the tubular. The span block includes sensor blocks with strain gauges that indirectly measure the load on the top drive by measuring the force applied to the span block itself. This intermediary approach enables precise load measurement without requiring complex sensors to be directly integrated into the top drive structure.
2Measurement precision
If multiple sensor blocks are positioned circumferentially about the span block, then the measurement precision and alignment accuracy are improved, but the device complexity increases
Solution Approach 1:
The measurement system is segmented into multiple independent sensor blocks positioned circumferentially around the span block. Each sensor block contains its own strain gauge and measures load in a specific direction. By dividing the measurement task across multiple segments, the system achieves comprehensive 3D load measurement and alignment detection while keeping each individual sensor block relatively simple in structure.
3Productivity
If a control system is implemented to adjust drilling operations based on sensor feedback, then the productivity and drilling efficiency are improved, but the device complexity increases
Solution Approach 1:
A control system is implemented that receives feedback signals from the strain gauges on the sensor blocks. The controller processes this feedback information about load and alignment conditions, and automatically adjusts drilling operations accordingly. This closed-loop feedback mechanism improves drilling efficiency by enabling real-time optimization while maintaining manageable system complexity through modular architecture.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables precise measurement and adjustment of load on top drives, improving drilling efficiency by ensuring proper alignment and reducing incidents of unsupported tubulars and drill strings.
Implementation Method 1
The reactive section is configured to deform in response to force applied to the sensor block
Implementation Method 2
Each sensor block of the plurality of sensor blocks comprises a sensor configured to output a signal indicative of the load applied to the top drive via the span block
Data Source
AI summary
A system includes a span block configured to couple with an extension from a top drive at a first end of the span block and configured to couple to a tubular at a second end of the span block. The system also includes a sensor block of the span block. The sensor block extends between the first end and the second end of the span block. Moreover, the sensor block is configured to provide an electronic indication of deformation of a portion of the sensor block in response to forces placed on the span block.